JP2018073329A - Production management system and production management method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a system capable of investigating causes of faults and product defects in real-time, and of appropriately predicting and preventing the occurrence of faults and product defects.SOLUTION: This system acquires first information from a metal mold electronic chart system 100, acquires second information from a production information gathering system 200, and third information from an information measurement support system 300. An information output unit 20 integrates the acquired first through third information, then links the acquired first through third information to a management index relating to at least one of the following: product quality, cost, productivity, and delivery date; and then outputs the linked first through third information and management index data as mapping data in a displayable manner.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a production management system and a production management method.

  At present, many companies, such as the manufacturing industry, use ERP (Enterprise Resource Planning) information management in order to standardize operations and unify information for sales, production, purchasing, manufacturing and accounting operations as the basis for management decisions aimed at overall optimization. A system using a platform is introduced.

Recently, in addition to building a management base, there is an increasing need for standardization including the manufacturing site, and management is also required to improve and optimize productivity in production activities. MES (Manufacturing Execution) Increasingly, companies are introducing manufacturing system management systems that are rich in real time (System). The main points of MES include the following points (see Patent Document 1).
・ Establish rapid and detailed traceability ・ Visualize manufacturing sites and respond quickly to problems ・ Improve various indicators such as yield and service level ・ Simple and quick collaboration with ERP

JP 2010-039733 A

ERP, MES, and more recently, IoT and IT management systems have been changing. Especially, the factories and production sites in the manufacturing industry have various variables as shown below. A failure or a product failure occurs, and the cause cannot be determined because of the combination, or the preventive / preventive measures cannot be appropriately performed. Therefore, various IT management systems have been proposed. However, Q (stable quality, defect reduction), D (delivery / speed improvement), C (cost reduction, productivity improvement, man-hour reduction) required by companies The current situation is that it has not contributed.
<Variable factors that may cause defects or product defects

(1) Failures / defect events on site cannot be grasped in real time. Events related to product defects, mold / facility failures cannot be collected in real time.

(2) Failure cause has not been identified In order to identify the cause of a product failure, the following information corresponding to the defective product is required.
・ Product material information ・ Manufacturing conditions related to equipment, molds, production lines, etc. ・ Maintenance information ・ Worker's work information related to product manufacturing

(3) Q (part quality), C (manufacturing cost), D (production cycle time, productivity) does not improve ・ Production conditions and mold conditions of production facilities are the number of production, daily conditions (temperature and humidity), etc. In addition, Q, C, and D are not stable because production fluctuates due to differences in the skills of workers. • Stop for a short time called a chocolate stop where equipment abnormalities occur, or stop for a long time in severe cases, and productivity does not increase. .

  In view of the circumstances as described above, an object of the present invention is to provide a production management system and a production management capable of investigating the cause of a defect or a product defect in real time and appropriately predicting and preventing the occurrence of the defect or the product defect. It is to provide a method.

  In order to solve such a problem, a production management system according to an aspect of the present invention includes a first information regarding a mold for molding a product or a jig for processing a product, and a product using the mold or the jig. An information collecting unit for collecting, in real time, second information relating to production equipment to be produced and third information relating to quality of products produced using the mold or jig and the production equipment using a communication network; , Integrating the collected first to third information, and linking the integrated first to third information with a management index related to at least one of quality, cost, productivity and delivery date of the product, An information generation unit that outputs the linked first to third information and the management index as mapping data in a displayable manner.

  In the present invention, the first to third information and the management index can be displayed as mapping data, for example, graphed data. Therefore, based on the displayed mapping data, the cause of the defect or the product defect can be determined. It is possible to investigate in real time and to appropriately predict and prevent the occurrence of defects and product defects.

  The first information includes at least one of the mold maintenance information, the cumulative shot number information of the mold, and worker information of a worker who has performed maintenance of the mold, and the second information. Is at least one of a molding cycle when the production facility molds a product using the mold, the number of production, molding conditions, temperature information of the mold, and environmental information about the environment where the production facility is arranged. It is one form that the third information includes at least one of the measurement information of the produced product and the worker information of the worker who measured the product.

  In one embodiment, the management index is at least one of a profit / loss limit line and a production condition limit line.

  It is preferable that the information generation unit associates a predetermined management index with predetermined first to third information according to an attribute of a person who views the mapping data in real time.

  A production management method according to an aspect of the present invention includes first information relating to a mold for molding a product or a jig for processing the product, and a production facility for producing the product using the mold or the jig. 2 and the third information relating to the quality of the product produced using the mold or tool and production equipment are collected in real time using a communication network, and the collected first to third information. And the integrated first to third information are linked to a management index related to at least one of quality, cost, productivity and delivery date of the product, and the linked first to third information and Display management indicators as mapping data.

  In the present invention, the cause of a defect or a product defect can be investigated in real time, and furthermore, the occurrence of a defect or a product defect can be appropriately predicted and prevented.

It is a block diagram which shows the structure of the production management system which concerns on one Embodiment of this invention. It is a block diagram which shows the structure of a metal mold | die medical chart system. It is a figure which shows the content of QR Code (trademark) used with the system of FIG. It is a figure which shows the content of the metal mold | die maintenance resume used by the system of FIG. It is a block diagram which shows the structure of a production information collection system. It is the figure which showed notionally the flow of the process of the data in the computer system in the production information collection system of FIG. It is a table | surface which shows an example of the data preserve | saved at the computer system in the production information collection system of FIG. It is a block diagram which shows the structure of a measurement assistance system. It is a block diagram which shows the structure of the server shown in FIG. It is a block diagram showing a flow from part ordering to delivery at a parts maker to receiving a part at a finished product maker. It is a figure which shows an example of the display of the prior confirmation information which concerns on one Embodiment of this invention. It is a figure which shows an example of the measurement table which concerns on one Embodiment of this invention. It is a figure for demonstrating creation of the measurement figure and measurement site | part figure which concern on one Embodiment of this invention. It is a figure which shows the example of the list of the calibration history information which concerns on one Embodiment of this invention. It is a figure which shows the calibration log | history information which made the caliper which concerns on one Embodiment of this invention into an example. It is a figure which shows an example of the information of the measuring method registered into the measuring method information database which concerns on one Embodiment of this invention. It is a figure which shows an example of the information managed with respect to the measurement table which concerns on one Embodiment of this invention. It is a flowchart which shows an example of the measurement procedure which concerns on one Embodiment of this invention. It is a flowchart which shows operation | movement of the program which performs the measurement and determination which concern on one Embodiment of this invention (the 1). It is a flowchart which shows operation | movement of the program which performs the measurement and determination which concern on one Embodiment of this invention (the 2). It is a figure which shows an example of the list | wrist (measurement result table) which concerns on one Embodiment of this invention. It is a figure which shows an example of the acceptance application which concerns on one Embodiment of this invention. It is a figure which shows an example of the acceptance test result which concerns on one Embodiment of this invention. It is a graph which shows the relationship between a shaping | molding cycle and time. It is a graph which shows the relationship between a molding cycle and the total number of shots. It is a specific example (the 1) of the mapping data which concerns on one Embodiment of this invention. It is a specific example (the 2) of the mapping data which concerns on one Embodiment of this invention. It is a specific example (the 3) of the mapping data which concerns on one Embodiment of this invention. It is a specific example (the 4) of the mapping data which concerns on one Embodiment of this invention. It is a figure for demonstrating presentation of the collection information according to the attribute of the person who browses the mapping data which concern on one Embodiment of this invention, and a management parameter | index. It is a graph which shows an example of the mapping data whose management index is a limit line of production conditions.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a block diagram showing a configuration of a production management system according to an embodiment of the present invention.
As shown in FIG. 1, the production management system 1 includes an information collection unit 10 and an information output unit 20.

The information collecting unit 10 uses the first information related to a mold for molding a product such as a part or a finished product, the second information related to a production facility for producing a product using the mold, and the mold and the production facility. It is typically composed of one or a distributed data server that collects third information on the quality of the produced product in real time using the communication network 2.
The information collecting unit 10 collects first information from the mold electronic medical record system 100, collects second information from the production information collecting system 200, and collects third information from the measurement support system 300.

  The information output unit 20 integrates the collected first to third information, and associates a management index related to at least one of product quality, cost, productivity, and delivery date with the integrated first to third information. The linked first to third information and management index data are output so as to be displayed as mapping data.

Typically, the tablet terminal 3 displays the mapping data on the screen based on the output data from the production management system 1.
<System configuration for collecting first information>
As shown in FIG. 2, the mold electronic medical record system 100 inputs first information about the mold 110 using the electronic device 120 during maintenance, and transmits the first information to the information collecting unit 10. is there.

  The mold 110 is a mold used for, for example, resin molding, press working, casting, forging, and the like. The mold 110 is a QR code (identifier for identifying the mold 110 that can be recognized as an image and recorded. An identification plate engraved with (registered trademark) 111 is provided at a predetermined position of the mold 110. The mold 110 includes mold parts such as an upper mold and a lower mold constituting the mold 110, and a QR code (registered trademark) may be given to each mold part.

  In the QR code (registered trademark) 111, for example, as shown in FIG. 3, in addition to the mold number of the mold 110 as identification data for identifying the mold 110, a customer name, product name, Data such as the mold manufacturing date, the mold designer, and the manufacturer of the mold are recorded. The identifier is not limited to a QR code (registered trademark), and a barcode, RFID, or the like may be used.

  The electronic device 120 is represented by, for example, a tablet terminal, a smartphone, and the like, and includes a camera 121 as an imaging unit capable of imaging a defective portion of the QR code (registered trademark) 111 and the mold 110, a microphone 122 capable of inputting sound, and the like. QR code for recognizing (recognizing) identification data from the touch pad 123 and display unit 124 that can input defect data of the mold 110 by pull-down operation, and the QR code (registered trademark) 111 captured by the camera 121 Audio data and touchpad input by the microphone 122 such as identification data recognized by the (registered trademark) recognition unit 125 and the QR code (registered trademark) recognition unit 125, imaging data of a defective part imaged by the camera 121, and the like. The defect data input by the network 123 And a WiFi communication unit 126 that transmits.

  Typically, during regular maintenance of the mold 110, the maintenance worker checks the state of the mold 110 and inputs the data to the electronic device 120. The mold maintenance resume shown in FIG. 4 shows a screen in which data is input for each item in the electronic device 120. The worker is also recognized by, for example, the QR code (registered trademark) of the employee plate, and is included in these data. Note that the maintenance date may be designated in the resume from the state of the mold and the number of shots, not periodically.

These data are the first information, and the first information is transmitted from the electronic device 120 to the information collecting unit 10 in real time via the network 2, and the information collecting unit 10 chronologically for each mold 110. The first information is automatically accumulated.
<System configuration for collecting second information>
As shown in FIG. 5, the production information collection system 200 is a system that collects production information in a factory 220 that produces parts using, for example, a plurality of processing machines 210A, 210B,.

  As the processing machines 210A, 210B,..., There are a molding machine, a press machine, a cutting machine, a grinding machine, an automatic casting and forging machine, and the like. For example, when the processing machines 210A, 210B,... Are molding machines, the production information is information based on data such as the number of moldings, molding temperature, molding pressure, molding time, and the like.

Each processing machine 210A, 210B,... Is provided with control units 211A, 211B,... And data output devices 212A- ₁ , 212A- ₂ , 212B- ₁ ,. The control units 211A, 211B,... Control the operations of the processing machines 210A, 210B,..., Suck up data for knowing the operation status and output them as logging data. The data output devices 212A- ₁ , 212A- ₂ , 212B- ₁ , ... output data not included in the logging data. The data output device 212A- ₁ is, for example, a temperature measuring device, and outputs analog data. The data output device 212A- ₂ is a switch on / off detector, for example, and outputs on / off data that is digital data.

The production information collection system 200 includes a plurality of slave units 202A- ₀ , 202A- ₁ , 202A- ₂ , 202B- _0, ... And a computer system 203. The plurality of slave units 202A- ₀ , 202A- ₁ , 202A- ₂ , 202B- _0, ... Are connected in series via the wiring 204. The computer system 203 accommodates the plurality of slave units 202A- ₀ , 202A- ₁ , 202A- ₂ , 202B- _0, ... Connected in series via the wiring 204. Of the plurality of slave units 202A- ₀ , 202A- ₁ , 202A- ₂ , 202B- _0, ..., A slave unit close to the computer system 203 side is defined as an upstream slave unit. In the example of FIG. 5, the slave unit 202A- ₀ is the most upstream slave unit. Note that a programmable logic controller (PLC) or the like may be used instead of the slave unit.

One or more slave units 202A- ₀ , 202A- ₁ , 202A- ₂ , 202B- ₀ ,... Are installed for each processing machine 210A, 210B,. In the example of FIG. 5, the processing machine 210A is provided with a control unit 211A, a data output device 212A- ₁ as a temperature measuring device, and a data output device 212A- ₂ as a switch on / off detector. Yes.

The data output device 212A- ₁ as a temperature measuring device outputs the data measured by the temperature measuring device as analog data. The data output device 212A- ₂ as a switch on / off detector outputs digital data corresponding to the opening / closing of the mold.

The control unit 211A is connected to the slave unit 202A- ₀ , the data output device 212A- ₁ is connected to the slave unit 202A- ₁ , and the data output device 212A- ₂ is connected to the slave unit 202B- ₂ .

Slave units 202A- ₀ , 202A- ₁ , 202A- ₂ , 202B- ₀ ... Function as slave stations and are included in logging data and logging data in response to a request from the computer system 203 as an upstream master station. It has a function of adding address data to the data not to be sent and sending the data upstream, and sending data from the downstream to the upstream.

For example, the slave unit 202A- ₀ sucks the logging data from the control unit 211A of the processing machine 210A, attaches the unique address data to the logging data in response to a request from the computer system 203, and flows it upstream. Receives this.

The slave unit 202A- ₁ has an A / D conversion function for converting analog data into digital data. In response to a request from the computer system 203, A / D conversion is performed on the measurement data (analog data) from the analog data temperature measuring device from the data output device 212A- ₁ of the processing machine 210A, and unique address data is attached to the digital data. The computer system 203 receives the data upstream.

In response to a request from the computer system 203, the slave unit 202A- ₂ attaches unique address data to the data from the data output device 212A- ₂ of the processing machine 210A and flows it upstream, and the computer system 203 receives this.

The computer system 203 functions as a master station for the slave station, and is not included in logging data and logging data with address data from each slave unit 202A- ₀ , 202A- ₁ , 202A- ₂ , 202B- ₀ ,. Data is input, predetermined data among the logging data is deleted, and the logging data after deletion and data not included in the logging data are stored. The computer system 203 is a PC, for example, and executes the above processing by an application that runs on a general-purpose OS such as Windows (registered trademark).

  FIG. 6 is a diagram conceptually showing the flow of data processing in the computer system 203.

Data input to the computer system 203 from the slave units 202A- ₀ , 202A- ₁ , 202A- ₂ , 202B- ₀ ... Via the wiring 204 is data including address data.

For example, address data is attached to logging data for data input from the slave unit 202A- ₀ to the computer system 203. The logging data includes, for example, various types of data from X _{1 to} X ₅ (for example, pressure data in a processing machine, temperature data at a predetermined position (mold temperature described later), operation time data, etc.) (reference numeral 2201). .

In the data input from the slave unit 202A- ₁ to the computer system 203, the address data is attached to the temperature data Y (reference numeral 2202).

In the data input from the slave unit 202A- ₂ to the computer system 203, address data is added to the on / off data Z (reference numeral 2203).

  Thereafter, these data are sequentially input to the computer system 203.

  The computer system 203 first attaches time data to these input data (reference numerals 2211 to 2213), and distributes them as data for each processing machine 210A, 210B,... According to the address data (reference numeral 2220).

Next, the computer system 203 deletes unnecessary data from the logging data. For example, in the processing machine 210A, X ₁ , X ₂ , and X ₅ are unnecessary among the logging data composed of X _{1 to} X ₅ , so these are deleted and the data of X ₃ and X ₄ are left ( 2230).

Finally, logging data consisting of X ₃ and X ₄ , temperature data Y, and on / off data Z are associated using time data as a key (reference numeral 2240). Then, as shown in FIG. 7, these data are accumulated in time units.

  These data are the second information, and the second information is transmitted from the computer system 203 to the information collecting unit 10 in real time via the network 2, and the information collecting unit 10 stores the second information in time series. Accumulated automatically.

  As described above, an identification plate 280 (see FIG. 5) on which a uniquely defined QR code (registered trademark) is engraved is attached to a mold used in the molding machine. This identification plate 280 is attached not only to the mold, but also to the processing machines 210A, 210B,.

  When the worker in the factory 220 attaches the mold to the molding machine, the QR code (registered trademark) and the metal plate of the identification plate 280 attached to the molding machine using an information processing apparatus with a camera such as a tablet terminal, for example. The QR code (registered trademark) of the identification plate 280 attached to the mold is recognized. Thereafter, the recognition data corresponding to the QR code (registered trademark) recognized by the application of the information processing apparatus is sent to the information collecting unit 10, and the information collecting unit 10 associates the data of the molding machine with the recognition data of the mold. . This makes it possible to know which mold the molding machine data uses, and to calculate the total number of shots of the mold.

Further, the information collecting unit 10 can know from the molding machine data, for example, under what conditions such as temperature and pressure the n-th shot was performed. Note that the number of production can be calculated from data of a counter that counts normal products to which a molding machine is attached, for example.
The manufacturing information for each shot is used for quality control for each individual product. In other words, it was a quality control method for each production lot, but this system records the quality of each individual product, can be used to narrow down defective products to a single unit, and build a system that does not produce a large number of defective products. can do. With this system, a so-called single guarantee can be realized.

In this production information collecting system 200, the computer system 203 deletes predetermined data from the logging data and stores the deleted logging data, so that the data to be saved can be reduced as much as possible. . The slave unit _202A -0 functions as a slave _station, 202A _-1, 202A -2, connect 202B _-0 · · · in series, these slave units _{202A -0, 202A -1, 202A -2} , 202B - machine 210A through ₀ ..., 210B, ... of the control unit 211A, 211B, ... and data output devices _{212A -1, 212A -2, 212B -1} , logging data and logging from ... Since data not included in the data is collected, new data output devices and new processing machines can be added easily. For example, when adding a new data output device or a new processing machine, somewhere between the slave units 202A- ₀ , 202A- ₁ , 202A- ₂ , 202B- ₀ ... connected in series, What is necessary is just to insert the new slave unit connected to the control unit of these new data output devices and a new processing machine in series. In the computer system 203, registration of predetermined data processing may be performed. Therefore, new data output devices and new processing machines can be easily added. That is, it is not necessary to consider the matching between the software version of the control unit and the version of the data output device as in the prior art. The slave units 202A- ₀ , 202A- ₁ , 202A- ₂ , 202B- _0, ... Function as slave stations for the computer system 203, and simply add address data to the data in response to a request from the master station. Therefore, it is not necessary to consider the matching of the software version of the computer system 203 with the software version of the control unit and the version of the data output device as in the prior art.

<System configuration for collecting third information>
As shown in FIG. 8, the measurement support system 300 includes a server 310 in the measurement support system 300, a PC 320 as an inspection terminal, and a PC 330 as a measurement table creation terminal. The server 310, the PC 320, and the PC 330 can perform data communication via the communication path 340, for example. The PC 320 and the PC 330 may be common.
The server 310 stores information for specifying each measurement site for a part having a plurality of measurement sites, a measuring instrument that measures each measurement site, information on a measurement method, and measurement points, which will be described later. It has a measuring instrument information database 3112 and a measuring method information database 3113.

  The PC 320 as an inspection terminal displays information for specifying each measurement site for a part based on information stored in a drawing / measurement information database 3111, a measuring instrument information database 3112, and a measurement method information database 3113, which will be described later. 1 display means, selection means for selecting a measurement site from the information displayed by the first display means, and a drawing / measurement information database 3111, a measuring instrument information database 3112, and a measurement method information database 3113 described later. And a second display means for displaying information on the measurement method, measurement method, and measurement point of the measurement site selected by the selection means. Here, the first and second display means are configured by a control unit and a display unit (display) of the PC 320. The selection means is constituted by a mouse or the like that the PC 320 has.

  As illustrated in FIG. 9, the server 310 includes a measurement information database 311, a linkage information database 312, and a measurement evaluation information database 313. The server 310 includes a control unit, a communication unit, and the like that are not illustrated. The server 310 transmits the third information to the information collecting unit 10 via the network 2 in real time.

  The measurement information database 311 includes a drawing / measurement information database 3111, a measuring instrument information database 3112, a measurement method information database 3113, a measurement information database 3114, and a measurement evaluation database 3115.

  The drawing / measurement information database 3111 includes measurement number information (information for specifying each measurement site for a part having a plurality of measurement sites), measurement value information, and tolerance information (upper / lower values) as information for a measurement drawing. ) (Dimension value and management tolerance of each measurement site) and measurement designated position information are stored.

  The measuring instrument information database 3112 stores digital measuring instrument information (measuring instrument that measures each measurement site), three-dimensional measuring instrument information, and surface roughness meter information as information for the measuring instrument, and information for calibration history. Calibration history inspection determination (pass / fail) information and inspection date information are stored, and maintenance maintenance determination (pass / fail) information and inspection date information are stored as information for maintenance.

  The measurement method information database 3113 includes, as measurement method information, shape classification information (hole / length / width / height classification), measurement device selection information (applicable measurement device selection), measurement method information (specific part, measurement procedure), The measurement reference position (measurement point information) is stored.

In the drawing / measurement information database 3111, the measuring instrument information database 3112, and the measurement method information database 3113 described above, each piece of information is stored for each part.
The measurement information database 3114 stores inspection date information, measurement dimension value information, measurer information, inspection determination (pass / fail) approver information, and inspection determination (pass / fail) information as dimension inspection information. Stores burr, rust, stain, color, and surface condition, stores hardness, surface roughness, and touch as special information, and stores supplier measurement table as acceptance inspection information.

In the measurement information database 3114, each piece of information is stored for each measured part.
The measurement evaluation database 3115 stores measurement value evaluation information, measurement value transition information (history), QC process management, and deviation values as dimension evaluation information, and stores statistical information by seven QC tools as statistical value information. The ISO regulation information is stored as information.

The cooperation information database 312 includes a design database 3121, a purchase database 3122, and a manufacturing database 3123.
The design database 3121 stores drawing information (product name, part name, product number, part number) and 3D data as 2D / 3D drawing information, and information other than the shape as specification information.
The purchase database 3122 stores manufacturing department / supplier information, supplier transaction information, and order information as supplier information.
The production database 3123 stores production lot information as production information.

  The measurement evaluation information database 313 stores measurement table data, statistical table data, and prediction analysis results as measurement evaluation information.

  This server 310 has a communication / warning function, and performs an abnormal value warning / mail, product certificate communication, design communication, biotechnical tool communication, security communication, etc. to an information browsing terminal (not shown).

  FIG. 10 is a block diagram showing the flow from part ordering to delivery at the parts maker to delivery of the parts at the finished product maker.

  As shown in FIG. 10, parts are ordered by purchasing, and manufacturing communication to the manufacturing department and measurement communication to the quality control department are performed. In parallel with manufacturing, the quality control department creates a measurement table. Measurement and determination are performed when a measurement part arrives from manufacturing. Then, upon delivery, an application for acceptance inspection and determination are made together with inspection data, and completion is declared.

  An example of creating a measurement table will be described. The measurement table is created as follows while an operator in the quality control department exchanges data with the server 310 by the PC 330.

  The operator reads information that needs to be confirmed in advance from the design database 3121, the purchase database 3122, and the manufacturing database 3123, and information that needs to be confirmed in advance, and displays the information on the screen of the PC 30. . FIG. 11 shows an example of the display.

  FIG. 12 is a diagram showing an example of a measurement table. The measurement table described below is typically created according to a measurement diagram creation support program.

  The operator inserts necessary information into the manufacturing information column 351 and the measurement component information column 352 of the measurement table 350 from the above-described prior information in the PC 330.

  The operator takes in the drawing information corresponding to the part to be measured from the design database 3121 of the linkage information database 312 of the server 310 in the PC 330 and inserts the measurement number (information for specifying the measurement site) to create a measurement diagram. Typically, as shown in FIG. 13, a measurement diagram 362 is created by two-dimensional CAD from a design drawing 361 as drawing information, and a measurement site diagram 363 for giving detailed instructions is created.

  Here, a measurement information ID is given to the measurement numbers (“1 in ○”, “2” in ○,...) In the measurement diagram 362, and the measurement information ID for each measurement number is assigned in advance. Registered in the measurement information database 3114.

  The operator inserts the measurement diagram 362 and the detailed measurement site diagram 363 in the measurement part information column 353 and the measurement number column 354 of the measurement table 350 in the PC 330. In addition, information other than precautions and illustrations should be entered as special notes.

  The operator designates a measuring instrument on the PC 330 from the measurement part diagram 363 or the like based on the size and shape of the measurement part. For the designation of the measuring instrument, for example, necessary information is read from the measuring information database 3114 or the measuring instrument information database 3112, and the measuring instrument is selected from past similar parts, or the measuring instrument is selected according to in-house measurement regulations.

  For example, a caliper is used as the groove width, a height gauge as the height, a micrometer or a caliper as the width, and a pin gauge as the hole.

  These measuring devices preferably output the measurement results as digital data. This is because the data can be directly taken in on the system side as will be described later. When the measuring device outputs the measurement result as analog data, the data may be input to the system side via the analog / digital converter. These digital data are typically input to the PC 320 via USB.

  Each measuring device is preferably provided with a QR code (registered trademark) including information for specifying the measuring device. This is because information for specifying the measuring instrument can be easily input to the system side as will be described later. QR code (registered trademark) read data is typically input to the PC 320 via a USB-connected reader or tablet terminal.

  The operator reads calibration history information from the measuring instrument information database 3112 in the PC 330, and performs calibration confirmation of the corresponding measuring instrument. FIG. 14 shows an example of a list of calibration history information, and FIG. 15 shows calibration history information taking calipers as an example. As shown in FIG. 15, the calibration history information includes a QR code (registered trademark) corresponding to the caliper (measuring instrument).

  The operator inserts the used measuring instrument, measuring instrument calibration information, and measuring instrument QR code (registered trademark) as measuring instrument information in the measuring instrument information column 356 of the measurement table 350 in the PC 330. The calibration information of the measuring instrument is a column for authenticating that the measuring instrument is authorized by the QR code (registered trademark). If it is certified, it is automatically changed from ○ to “Black”. ing.

The operator reads the measurement method information from the measurement method information database 3113 in the PC 330 and determines the measurement method and the measurement point for each measurement number (measurement site). FIG. 16 shows an example of measurement method information registered in the measurement method information database 3113. For example, the groove width is as follows: ・ The bottom surface is the reference surface ・ Measure with a caliper bevel perpendicular to the measurement groove ・ The caliper beak should be set 1 mm above the bottom of the groove ・ Measured three times at one place and averaged Establish measurement methods such as adopting values.
The determined measurement method and measurement point are assigned a measurement information ID for each measurement number.

  In the measurement of parts, the measurement method is an important factor in measurement evaluation. If the measurement method is not correct or not appropriate, the evaluation varies and the reliability is lost. In particular, since the product is twisted, the measurement standard (surface) is important. In addition, it is necessary to prevent measurement from being dispersed, specifically to be specified in a measurement manual. Therefore, the measurement method is stored in the measurement method information database 3113 so that it can be set semi-automatically.

  A measurement point is information that defines a place to be measured at a measurement site. Typically, a measurement standard (line) and a point on the line are defined in a 3D drawing. Specifically, the measurement point is defined as “measurement is performed near the points a and b on the measurement reference line” as shown in the measurement point column of the measurement information column 357 shown in FIG. That's it.

  The operator inserts a measurement method and a measurement point as measurement information in the measurement information column 357 of the measurement table 350 in the PC 330.

  The above creation work of the measurement table 350 is performed for each measurement number (measurement site). Thereby, measurement part information, special remarks, measuring instrument information, measurement method, and measurement point are determined for each measurement number (measurement part) for one piece of manufacturing information, part information, and part diagram information. Such information of the measurement table 350 is once registered in the measurement information database 3114.

  Here, the above measurement information ID is uniquely determined for each measurement number. For example, as shown in FIG. 17, the measurement number, the measurement information ID, the part measurement diagram, the measuring instrument, the measurement method, and the like are associated as information for the measurement table 350. Managed.

  FIG. 18 is a flowchart showing an example of a measurement procedure.

  First, the measurer uses the PC 320 to read a QR code (registered trademark) including information on the manufacturing part ID (LOT management ID) attached to the manufacturing pallet (container for storing parts) (step 101).

  Next, the measurer reads a QR code (registered trademark) including information of the measurer ID printed on the employee slip using the PC 320 (step 102). If the measurer ID is approved, the ID is registered.

  On the screen of the PC 320, a measurement table corresponding to the component recognized in step 101 is read (see FIG. 12) and displayed. When the measurer ID has been approved, the measurer's display in the measurement value information column 358 of the measurement table shown in FIG.

  Next, the operator clicks one of the measurement numbers displayed in the part information in the measurement part information column 353 of the measurement table 350 displayed on the PC 320 (step 103). Then, in the measurement number column 354 of the measurement table 350 on the screen of the PC 320, measurement site information and special notes corresponding to the measurement number are used, and in the measurement device information column 356, the measurement instrument used and the measurement QR code (registered trademark) corresponding to the measurement number are registered. In the measurement information column 357, the measurement method and measurement point corresponding to the measurement number are displayed.

  Next, the operator selects a measuring instrument corresponding to the measuring instrument used displayed in the measuring instrument information column 356 and reads the QR code (registered trademark) in the measuring instrument (step 104). It is determined whether or not the measuring instrument has been calibrated. If the measuring instrument has been calibrated, the measuring instrument calibration information in the measuring instrument information column 356 is displayed as “black”. On the other hand, when the calibration is not completed, the display of the measurement instrument calibration information remains ◯, and even if measurement is performed using the measurement instrument in this state, the measurement data is not adopted as the measurement result. As a result, it is possible to prevent measurement by a measuring instrument that has not been calibrated.

  Next, the operator performs measurement with the measuring instrument according to the information (manual) displayed in the measurement number column 354 and the measurement information column 357 of the measurement table 350 on the screen of the PC 320 (step 105).

  In the measurement value information column 358 of the measurement table 350, the dimension value, the management tolerance upper limit, and the lower limit on the drawing of the part are displayed in advance, and the measurement results are sequentially displayed. In PC320, if it is within the range of the control value tolerance based on the measurement result, it is determined to be acceptable if it is outside the range of the management value tolerance, and if it is acceptable, the measurement result in the measurement value information column 358 of the measurement table 350 is determined. “OK” is displayed on the right side. Note that if the measurement result is in a range that is further outside the range of the control value tolerance, it is determined that there is an abnormality. For example, “No abnormality” in the remarks in the measurement value information column 358 of the measurement table 350 remains ○, A mail for notifying the occurrence of a defect is automatically transmitted. When the mail is transmitted, “abnormal communication (automatic contact mail transmission)” in the remarks of the measurement value information column 358 of the measurement table 350 is displayed from “◯” to “black”. In addition, when the special items and special inspection are checked, “OK” is displayed on the right side of these columns.

The measurer performs the above measurement operations from Step 103 to Step 105 for all measurement numbers.
The PC 320 has a program for executing the above measurement and determination.
19A and 19B are flowcharts showing the operation of the program.
When manufacturing part ID (LOT management ID) information is input (step 111) and measurer ID information is input (step 112), whether or not the measurer ID may be approved is based on information from the server 310. Judgment is made (step 113). If YES in step 113, measurement table data corresponding to the information of the manufactured part ID (LOT management ID) is obtained from the server 310 (step 114). Then, a measurement table corresponding to the part is displayed (step 115). The display of the measurer in the measurement value information column 358 is “black circle”.

  Waiting for one of the measurement numbers to be clicked (step 116), when clicked, the measurement site information corresponding to the clicked measurement number, special notes, measuring instrument used, measurement QR code (registered trademark), measurement The method and measurement points are displayed (step 117).

  Waiting for the input of information for specifying the measuring instrument (step 118), when the information is input, it is determined based on the information from the server 310 whether the measuring instrument has been calibrated (step 119). When the calibration has been completed, the display of the measurement device calibration information in the measurement device information column 356 is changed from “◯” to “black” (step 120). On the other hand, if the calibration has not been completed, the display of the calibration information of the measuring instrument is left as ◯, and the input data from the measuring instrument is not adopted (step 121).

  If configured in step 120, the input data from the measuring instrument is displayed (step 122) and it is determined whether it is within the control tolerance (step 123). Steps 122 and 123 are repeated a predetermined number of times (step 124).

  If all are within the range of the control value tolerance, it is determined that the pass is acceptable, and if it is outside the range of the control value tolerance, the failure is determined (step 125), and a predetermined display is performed (step 126). If the measurement result is in a range that is further outside the range of the control value tolerance (step 127), it is determined that there is an abnormality, and the display and mail transmission are performed (step 128).

  Step 116 and subsequent steps are executed for all measurement numbers (step 129) and a list (measurement result table) is created (step 130), a predetermined display and an e-mail to the approver are transmitted (step 131). finish. FIG. 20 shows an example of the list. The approver approves based on this list. Approval is performed as electronic approval on the PC, and when approved, for example, the display in the comprehensive judgment column of the list changes from ○ to “black”. Thereafter, the list is automatically notified to the delivery department by e-mail.

  The above measurement data is stored in the server 310 in real time. This measurement data is the third information, and the third information is transmitted from the server 310 to the information collecting unit 10 in real time via the network 2, and the information collecting unit 10 automatically converts the second information in time series. Accumulated.

  In addition, supplier side realizes acceptance inspection-less by confirming and approving input according to the system prepared by ordering side. Denied if input is incomplete. For example, the ordering side accesses the server 310 on the supplier side, obtains the acceptance application shown in FIG. 21, and issues the acceptance inspection result shown in FIG. That is, in the past, measurement and determination of delivered parts were also performed on the ordering side, but according to the present invention, such measurement and determination on the ordering side is not necessary, and the ordering side displays the measurement and determination results on the supplier side. Parts can be accepted as they are. In other words, (1) Measuring instruments, measuring methods, etc. are called for the measurement number, so there is no need for various manuals, documents, confirmation actions, and training for operators. (2) Measuring instruments with calibrated measuring instruments Otherwise, the automatic measurement system will not work, that is, if the measurement instrument specified by the measurement number is “calibrated” and the instrument does not match, automatic measurement will not be entered. (3) All measuring instruments use digital instruments. By doing this, the measurement table is automatically created, and there is no need to fill in the dimension of the measurement table. (Trademark), QR code (registered trademark) of the measuring instrument and its calibration guarantee, and QR code (registered trademark) of the measurer and approver, "When, who, which product, what, and how," Is all digital information It is recorded. Therefore, “measurement reliability” can be guaranteed, and an acceptance inspection on the ordering side can be made unnecessary.

  Moreover, although the QR code (registered trademark) is provided on the manufacturing pallet (container for storing the parts), the part itself may be provided with the QR code (registered trademark). In addition, the PC is described as an example of the inspection terminal, but other terminals such as a tablet terminal can be used as the inspection terminal.

<Generation of mapping data>
As described above, the information collection unit 10 collects the first information, typically the information input in the mold maintenance resume shown in FIG. 4, from the mold electronic medical record system 100, and the second information The information, typically the production log information shown in FIG. 7, is collected from the production information collection system 200, the second information is entered into the third information, typically the measurement table shown in FIG. Information is collected from the measurement support system 300.
The information collecting unit 10 stores the collected first to third information in association with each mold. Specifically, for each die, maintenance information of the die, production log information using the die, and measurement information of a product (part) molded using the die are stored in association with each other.

  The information collecting unit 10 stores a management index related to at least one of product quality, cost, productivity, and delivery date in association with each mold. As a management index, there is typically a profit / loss margin line of a product molded by the mold. As the management index, for example, a value set in another system in the factory may be captured.

  The information output unit 20 integrates the first to third information collected for each mold, associates a management index with the integrated first to third information, and outputs these as displayable mapping data. The information output unit 20 may output these pieces of information to the tablet terminal 3, and the tablet terminal 3 may display mapping data from these pieces of information on a screen using predetermined software. The information output unit 20 may output mapping data to the tablet terminal 3, and the tablet terminal 3 may display the mapping data on the screen.

  In general, in molding using a mold, the molding time gradually increases depending on the use of the mold. In the production management system 1 according to this embodiment, the reason why the molding cycle is extended can be examined.

Factors affecting the molding cycle are:
・ Deterioration of mold, change of material, change of manufacturing conditions, change of molding machine environment, fluctuation of molding condition setting are assumed.

  In this production management system 1, for example, mold maintenance (gas burn, wear), cumulative shot number, mold clogging, hot spot (cavity / core slide), etc. are collected as mold information from the mold electronic medical record system 100. From the production information collection system 200, for example, molding cycle time, production number / production lot, molding conditions / cooling water temperature / molding temperature (mold temperature / water pipe temperature), molding machine environment / factory temperature, etc. are collected. For example, component accuracy measurement values, surface states (burrs, sink marks, whitening), statistical analysis values, and the like are collected from the measurement support system 300 as measurement information.

As the logic of the factor analysis for the excess of the molding cycle, for example, as follows, information related to each factor is combined and analyzed.
-Deterioration of mold-Cumulative number of shots-Maintenance-Deterioration status-Change in part accuracy-Statistical analysis-Change in material-Molding material-Change in factory temperature and humidity-Manufacturing conditions-Molding cycle-Molding temperature-Mold temperature-Cooling Water temperature-Molding date / time and molding machine environment change-Equipment maintenance-Factory temperature / humidity-Molding machine temperature / humidity-Power fluctuation

In this production management system 1, the above-mentioned data is displayed on the screen as mapping data, and for example, the management side can extract factors affecting the molding cycle while viewing it.
For example, for resin component manufacturers, molding cycle time greatly affects profits. FIG. 23 shows an example of the transition of the time-series molding cycle of resin molded parts, and it can be seen that the molding time increases with time and eventually exceeds the profit / loss margin line.

A specific example of mapping data for extracting the above factors is shown below.
Specific example of mapping data (FIG. 25) (1)
If the molding cycle is graphed as shown in FIG. 23 from the log information of the molding machine, which is production information, from the production information collection system 200, and the cumulative shot number is graphed in time series as shown in FIG. From this graph, it is possible to read from which point the time is over, or the trend and branch / change points.
When mapping analysis of the two graphs shown in FIG. 23 and FIG. 24 is performed as shown in FIG. 25, when the cumulative number of shots of the mold exceeds 98,000 times, it becomes a branching point and the molding cycle of the profit / loss margin line is exceeded. I understand that.
Specific example of mapping data (FIG. 26) (part 2)
It is also possible to map and analyze the relationship between the timing of mold maintenance and the total number of shots at that time.

  Here, as for the maintenance of the mold, since regular deterioration of the mold cannot be predicted, regular maintenance is mainstream. However, there are fluctuations in the number of production orders, which are carried out regardless of the cumulative number of shots. In practice, however, the molding cycle is clearly reduced after mold maintenance. In addition, the molding cycle clearly tends to increase without maintenance. Therefore, it is necessary to perform mold maintenance at an appropriate timing.

As shown in FIG. 26, by analyzing the mold maintenance history information which is the mold information from the mold electronic medical record system 100, it is possible to identify the parts and parts of the mold deterioration and to predict the mold maintenance time. Become.
Specific example of mapping data (FIG. 27) (part 3)
From the information on the mold maintenance resume shown in Fig. 4, it is possible to read the conversion points of mold parts and parts for the increase in molding cycle, which can be used for room and prevention of mold maintenance.
Here, the temperature associated with the mold changes during the injection molding process. In the production information collection system 200, time-series changes in temperature are recorded as production information for each time-series (number of molding shots) using a temperature sensor.

From the mapping data shown in FIG. 27, it can be seen that the reason why the molding cycle after 98,000 shots is extended is due to the temperature change of the mold cooling water. The cause of the cooling water temperature change can be checked from the information on the mold maintenance resume shown in Fig. 4 for the rust of the mold cooling pipe, etc. The factory environment and the temperature rise of the molding machine can also be considered. Can also be guessed. The temperature drop in the whole factory due to the temperature drop in winter is also considered a factor.
Specific example (part 4) of mapping data (FIG. 28)
Judgment for an increase in molding cycle time is also related to part (product) accuracy. The production management system 1 collects part accuracy information from the measurement support system 300 as measurement information.

The mapping data shown in FIG. 28 includes component accuracy information. From this mapping data, while looking at the parts accuracy information, mold maintenance time, remanufacturing mold parts, cooling water and mold temperature settings, molding machine settings (holding pressure, nozzle temperature, etc.), etc. Can be appropriately determined in real time.
In the above mapping data, the profit and loss limit line has been described as an example of the management index. However, the production condition limit line, the mold temperature limit line, the nozzle temperature limit line, and the like may be used as the management index. Two or more management indexes may be simultaneously displayed as mapping data. Here, FIG. 30 shows an example of mapping data in which the management index is a production condition limit line. FIG. 30 shows the relationship between the number of shots in the mold and the molding cycle time. When the molding cycle time exceeds 30 seconds, it can be known in real time that the molding cycle time as a production condition exceeds the limit line.

<Presentation of collected information and management indicators according to the attributes of the person browsing the mapping data>
One of the objects of the present invention is to collect “people / things / data / information” at the manufacturing site in real time from the mold electronic medical record system 100, the production information collection system 200, and the measurement support system 300. Process data from the viewpoints of (C), quality (Q), delivery time (D), and productivity (P), graph it, and provide monitoring information from the viewpoints of business management, factory management, and line management, to respond quickly (1) Management monitoring function Presents QCDP monitoring indicators from the viewpoint of company-wide management. In recent years, globalization has increased the number of companies that have manufacturing bases in Japan and overseas, and it has become necessary to collectively process profits of manufacturing departments and manufacturing information for each base and use them as a company-wide management index. In addition, suppliers who outsource parts manufacturing have a global supply system, and there are hundreds of manufacturing companies for each product, and it is necessary to manage the production throughout the group.

(2) Factory monitoring function Presents the QCDP monitoring index for the entire factory that aggregates information on each production line from the viewpoint of factory management. The factory has production lines and assembly lines for parts and products. Aggregate these data and provide management indicators at the factory level

(3) Line monitoring function QCDP monitoring index is presented for each part manufacturing / assembly line in the factory. The production line is composed of workers, equipment, molds, inspection machines, and the like necessary for manufacturing each part. Each data is indexed and graphed according to each management item.

In the production management system 1 according to the present invention, as shown in FIG. 29, the monitoring indicators for management, factory, and line are classified into C: cost, Q: quality, D: delivery date, and P: productivity management categories. Indexed, according to the person in the management position, factory position, line position, that is, according to the attribute of the person viewing the mapping data, according to the attribute of the person on the display screen of that person's terminal The collected information and management index mapping data are configured and presented. Further, for example, by pressing a button on the terminal display screen, a management category that the person wants to view is selected, and mapping data is configured and presented accordingly. Of course, the desired mapping data may adopt a mechanism for restricting the viewers by security.
<Others>
The present invention is not limited to the above-described embodiment, and can be modified and implemented within the scope of the technical idea, and is within the scope of the present invention within the scope of the embodiment.

  In the above-described embodiment, the mold has been described as an example, but the present invention can be applied even to a jig for processing a product.

  The first to third information according to the present invention, that is, the variation factors to be converted into mapping data are various as exemplified below.

  For example, in the parts manufacturing site in the case of automobiles and home appliances, if the variable factors related to Q, C, D are listed, for resin parts, press parts, cast parts, forged parts, rubber parts, etc. that use molds, It is as follows

(1) Variations in production conditions of production equipment and production lines ・ Setting conditions of production machines (resin molding machines, press machines, casting machines, forging machines, rubber molding machines, etc.) ・ Auxiliary equipment of production machines (temperature controllers, material supply) Setting conditions for equipment, parts picking / conveying robot, refueling equipment, etc.) Setting conditions for equipment / factory building production sites (temperature, humidity, vibration, dust, airflow, etc.)

(2) Mold / mold component state variation ・ Mold state and maintenance variation (wear, gas adhesion, dirt, rust, deformation, breakage, etc., changes due to maintenance)
・ In-mold fluctuation during production (mold temperature rise / fall, mold pressure fluctuation)
・ Mold auxiliary parts (hot runner, gas injection machine, film insertion machine, etc.)

(3) Fluctuations in human work-Fluctuations due to differences in human work skills (machine operation, finishing, maintenance, visual work, wasted work, etc.)
・ Variations caused by workers (erroneous work, skipping of processes, erroneous entry, retention between processes, lack of man-hours, etc.)
In addition, the fluctuation factors of the cutting process parts that directly process the material are the same as the former, but since the tool is used instead of the mold, it is as follows.

(1) Variations in production conditions of production equipment and production lines ・ Setting conditions of production machines (cutting machines, electric discharge machines, polishing machines, etc.) ・ Maintenance status of the equipment (accuracy correction)
・ Setting conditions of machining data (NC data) ・ Setting conditions of production equipment incidental equipment (rotary table, transfer robot, cutting oil equipment, etc.) ・ Environment at the production site of equipment / factory building (temperature, humidity, vibration, dust, Cutting powder, airflow, etc.)

(2) Jig and tool condition fluctuations ・ Cutting tool condition (wear, accuracy of setting with tool holder, etc.) and maintenance fluctuation (re-grinding)

(3) Changes in human work ・ Changes due to differences in human work skills (setup work, machine operation, inspection, useless work, etc.)
・ Variations caused by workers (erroneous work, skipping of processes, erroneous entry, retention between processes, lack of man-hours, etc.)

DESCRIPTION OF SYMBOLS 1 Production management system 2 Communication network 10 Information collection part 20 Information output part 100 Mold electronic medical record system 200 Production information collection system 300 Measurement support system

Claims (5)

1st information regarding the metal mold | die which shape | molds a product, or the tool which processes a product, 2nd information regarding the production equipment which produces a product using the said metal mold | die or a jig | tool, the said metal mold | die or jig | tool, and the said An information collection unit that collects third information on the quality of products produced using the production facility in real time using a communication network;
The collected first to third information is integrated, and the integrated first to third information is combined with a management index related to at least one of quality, cost, productivity, and delivery date of the product, A production management system comprising: an information generation unit that outputs the linked first to third information and management index as mapping data so as to be displayed. The production management system according to claim 1,
The first information includes at least one of maintenance information of the mold, cumulative shot number information of the mold, and worker information of a worker who performed maintenance of the mold,
The second information includes the molding cycle when the production facility molds a product using the mold, the number of production, molding conditions, temperature information of the mold, and environmental information regarding the environment in which the production facility is arranged. At least one of
The production management system, wherein the third information includes at least one of measurement information of the produced product and worker information of a worker who measured the product. The production management system according to claim 1 or 2,
The management index is at least one of a profit and loss limit line and a production condition limit line. The production management system according to any one of claims 1 to 3,
The information generation unit associates a predetermined management index with predetermined first to third information according to an attribute of a person viewing the mapping data. 1st information regarding the metal mold | die which shape | molds a product, or the tool which processes a product, 2nd information regarding the production equipment which produces the said product using the said metal mold | die or a tool, and the said metal mold | die or jig | tool, and Collect third information on the quality of products produced using production equipment in real time using a communication network,
Integrating the collected first to third information,
The integrated first to third information is linked to a management index related to at least one of the quality, cost, productivity and delivery date of the product,
A production management method for displaying the linked first to third information and management index as mapping data.